Mazda Car 2002-04

Camshaft, Bearings & Lifters 4

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Removal & Installation



2.5L (Kl) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Intake manifold
     
    Fuel hose
     
    Cylinder head cover
     
    Camshaft sprocket bolt by holding the camshaft with a wrench on the hexagon cast into the camshaft
     
    Upper radiator hose
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Water outlet
     

  10.  
  11. Turn the camshaft, using a wrench on the cast hexagon, until the camshaft knock pin is aligned with the cylinder head marks.
  12.  


    Click image to see an enlarged view

    Fig. Front camshaft cap bolt loosening sequence-626 with 2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-626 with 2.5L (KL) engines



NOTE
Do not remove the camshaft caps when the camshaft lobe is pressing on a lifter, as the thrust journal support may become damaged.

  1. Loosen the front camshaft cap bolts in 5-6 steps, in the proper sequence. BoltA
  2.  
  3. Mark the position of the camshaft caps so they can be reinstalled in their original locations. Loosen the remaining camshaft cap bolts in 5-6 steps, in the proper sequence, then remove the caps.
  4.  
  5. Remove or disconnect the following:

    camshafts
     
    Lifters and adjustment shims, if necessary
     

  6.  


NOTE
Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

To install:

  1. Install or connect the following:

    Lifters in their original positions lubricated with engine oil. Verify that they move smoothly in their bore.
     
    Camshafts by lubricating the camshaft journals, lobes and gears with clean engine oil and aligning the timing marks
     

  2.  


NOTE
The thrust plate positions for the right and left cylinder head camshafts are different.



Click image to see an enlarged view

Fig. When installing the camshafts, ensure that the marks on the cam gears are aligned-2.3L and 2.5L engines



Click image to see an enlarged view

Fig. Put silicone sealant on the cylinder head at the positions shown-626 with 2.5L (KL) engines



Click image to see an enlarged view

Fig. Front camshaft cap bolt tightening sequence-626 with 2.5L (KL) engines



Click image to see an enlarged view

Fig. Camshaft cap bolt tightening sequence-626 with 2.5L (KL) engines

  1. Be sure the camshaft cap and cylinder head surfaces are clean. Apply a small amount of sealant to the mating surface of the front camshaft cap on both cylinder heads and the rear exhaust camshaft cap on the left cylinder head. Do not get any sealant on the camshaft rotating surfaces.
  2.  
  3. Install or connect the following:

    front camshaft caps and thrust plate caps. Torque the bolts until the cap seats fully to the cylinder head.
     
    Remaining caps in their original locations. Torque the bolts in 5-6 steps to 126 inch lbs. (14 Nm), in the proper sequence.
     
    New oil seals in the cylinder head using an installer
     
    New blind cap coated with sealant, tap it in place using a plastic hammer
     
    camshaft sprockets
     

  4.  


NOTE
On the right cylinder head, install the sprocket so the R mark can be seen and the timing mark aligns with the camshaft knock pin. On the left cylinder head, install the sprocket so the L mark can be seen and the timing mark aligns with the camshaft knock pin.



Camshaft sprocket bolts lubricated with engine oil, by holding the camshaft with a wrench on the cast hexagon. Torque the bolt to 97 ft. lbs. (132 Nm).
 
Water outlet
 
Seal plate
 
Number 3 engine mount bracket
 
Upper radiator hose
 
Camshaft pulley. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 90-97 ft. lbs. (123-132 Nm).
 
Cylinder head cover
 
Fuel hose
 
Intake manifold
 
Air cleaner assembly
 
Front exhaust pipe
 
Timing belt
 
Negative battery cable
 

  1. Fill and bleed the cooling system.
  2.  
  3. Change the oil and filter.
  4.  
  5. Run the engine and check for proper operation.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Air cleaner assembly
     
    Spark plug wires
     
    Distributor
     
    Intake manifold
     
    Upper radiator hose
     
    Water outlet
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Front exhaust pipe
     
    Alternator stay
     
    Cylinder head cover
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     

  10.  
  11. Turn the camshaft, using a wrench on the cast hexagon, until the camshaft knock pin is aligned with the cylinder head marks.
  12.  


    Click image to see an enlarged view

    Fig. Front camshaft cap bolt loosening sequence-2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-2.5L (KL) engines



NOTE
Do not remove the camshaft caps when the camshaft lobe is pressing on a lifter, as the thrust journal support may become damaged.

  1. Loosen the front camshaft cap bolts in 5-6 steps, in the proper sequence. BoltA
  2.  
  3. Mark the position of the camshaft caps so they can be reinstalled in their original locations. Loosen the remaining camshaft cap bolts in 5-6 steps, in the proper sequence, then remove the caps.
  4.  
  5. Remove or disconnect the following:

    camshafts
     
    Lifters and adjustment shims, if necessary
     

  6.  


NOTE
Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

To install:

  1. Install or connect the following:

    Lifters in their original positions lubricated with engine oil. Verify that they move smoothly in their bore.
     
    Camshafts by lubricating the camshaft journals, lobes and gears with clean engine oil and aligning the timing marks
     

  2.  


NOTE
The thrust plate positions for the right and left cylinder head camshafts are different.



Click image to see an enlarged view

Fig. When installing the camshafts, ensure that the marks on the cam gears are aligned-2.5L (KL) engines



Click image to see an enlarged view

Fig. Put silicone sealant on the cylinder head at the positions shown-2.5L (KL) engines



Click image to see an enlarged view

Fig. Front camshaft cap bolt tightening sequence-2.5L (KL) engines



Click image to see an enlarged view

Fig. Camshaft cap bolt tightening sequence-2.5L (KL) engines

  1. Be sure the camshaft cap and cylinder head surfaces are clean. Apply a small amount of sealant to the mating surface of the front camshaft cap on both cylinder heads and the rear exhaust camshaft cap on the left cylinder head. Do not get any sealant on the camshaft rotating surfaces.
  2.  
  3. Install or connect the following:

    front camshaft caps and thrust plate caps. Torque the bolts until the cap seats fully to the cylinder head.
     
    Remaining caps in their original locations. Torque the bolts in 5-6 steps to 126 inch lbs. (14 Nm), in the proper sequence.
     
    New oil seals in the cylinder head using an installer
     
    New blind cap coated with sealant, tap it in place using a plastic hammer
     
    camshaft sprockets
     

  4.  


NOTE
On the right cylinder head, install the sprocket so the R mark can be seen and the timing mark aligns with the camshaft knock pin. On the left cylinder head, install the sprocket so the L mark can be seen and the timing mark aligns with the camshaft knock pin.



Camshaft sprocket bolts lubricated with engine oil, by holding the camshaft with a wrench on the cast hexagon. Torque the bolt to 97 ft. lbs. (132 Nm).
 
Cylinder head cover
 
Alternator stay
 
Front exhaust pipe
 
Seal plate
 
Number 3 engine mount bracket
 
Water outlet
 
Upper radiator hose
 
Intake manifold
 
Distributor and spark plug wires
 
Air cleaner assembly
 
Timing belt
 
Negative battery cable
 

  1. Fill and bleed the cooling system.
  2.  
  3. Change the oil and filter.
  4.  
  5. Run the engine and check for proper operation.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Intake manifold
     
    Fuel hose
     
    Cylinder head cover
     
    Camshaft sprocket bolt by holding the camshaft with a wrench on the hexagon cast into the camshaft
     
    Upper radiator hose
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Water outlet

    Click image to see an enlarged view

    Fig. Front camshaft cap bolt loosening sequence-626 with 2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-626 with 2.5L (KL) engines

     

  10.  
  11. Turn the camshaft, using a wrench on the cast hexagon, until the camshaft knock pin is aligned with the cylinder head marks.
    NOTE
    Do not remove the camshaft caps when the camshaft lobe is pressing on a lifter, as the thrust journal support may become damaged.

  12.  
  13. Loosen the front camshaft cap bolts in 5-6 steps, in the proper sequence. Bolt A is only on the right cylinder head. Remove the front camshaft cap.
  14.  
  15. Mark the position of the camshaft caps so they can be reinstalled in their original locations. Loosen the remaining camshaft cap bolts in 5-6 steps, in the proper sequence, then remove the caps.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Identify and mark each lifter as it is removed so it can be reinstalled in the same position.



    Camshafts
     
    Lifters and adjustment shims, if necessary
     

  18.  

To install:

  1. Install or connect the following:
    NOTE
    The thrust plate positions for the right and left cylinder head camshafts are different.



    Lifters in their original positions lubricated with engine oil. Verify that they move smoothly in their bore.
     
    Camshafts by lubricating the camshaft journals, lobes and gears with clean engine oil and aligning the timing marks
     



    Click image to see an enlarged view

    Fig. When installing the camshafts, ensure that the marks on the cam gears are aligned-2.3L and 2.5L engines



    Click image to see an enlarged view

    Fig. Put silicone sealant on the cylinder head at the positions shown-626 with 2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Front camshaft cap bolt tightening sequence-626 with 2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-626 with 2.5L (KL) engines

  2.  
  3. Be sure the camshaft cap and cylinder head surfaces are clean. Apply a small amount of sealant to the mating surface of the front camshaft cap on both cylinder heads and the rear exhaust camshaft cap on the left cylinder head. Do not get any sealant on the camshaft rotating surfaces.
  4.  
  5. Install or connect the following:
    NOTE
    On the right cylinder head, install the sprocket so the R mark can be seen and the timing mark aligns with the camshaft knock pin. On the left cylinder head, install the sprocket so the L mark can be seen and the timing mark aligns with the camshaft knock pin.



    Front camshaft caps and thrust plate caps. Torque the bolts until the cap seats fully to the cylinder head.
     
    Remaining caps in their original locations. Torque the bolts in 5-6 steps to 126 inch lbs. (14 Nm), in the proper sequence.
     
    New oil seals in the cylinder head using an installer
     
    New blind cap coated with sealant, tap it in place using a plastic hammer
     
    Camshaft sprockets
     



    Camshaft sprocket bolts lubricated with engine oil, by holding the camshaft with a wrench on the cast hexagon. Torque the bolt to 97 ft. lbs. (132 Nm).
     
    Water outlet
     
    Seal plate
     
    Number 3 engine mount bracket
     
    Upper radiator hose
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 90-97 ft. lbs. (123-132 Nm).
     
    Cylinder head cover
     
    Fuel hose
     
    Intake manifold
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Change the oil and filter.
  10.  
  11. Run the engine and check for proper operation.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Air cleaner assembly
     
    Spark plug wires
     
    Distributor
     
    Intake manifold
     
    Upper radiator hose
     
    Water outlet
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Front exhaust pipe
     
    Alternator stay
     
    Cylinder head cover
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.

    Click image to see an enlarged view

    Fig. Front camshaft cap bolt loosening sequence-2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-2.5L (KL) engines

     

  10.  
  11. Turn the camshaft, using a wrench on the cast hexagon, until the camshaft knock pin is aligned with the cylinder head marks.
    NOTE
    Do not remove the camshaft caps when the camshaft lobe is pressing on a lifter, as the thrust journal support may become damaged.

  12.  
  13. Loosen the front camshaft cap bolts in 5-6 steps, in the proper sequence. Bolt A is only on the right cylinder head. Remove the front camshaft cap.
  14.  
  15. Mark the position of the camshaft caps so they can be reinstalled in their original locations. Loosen the remaining camshaft cap bolts in 5-6 steps, in the proper sequence, then remove the caps.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Identify and mark each lifter as it is removed so it can be reinstalled in the same position.



    Camshafts
     
    Lifters and adjustment shims, if necessary
     

  18.  

To install:

  1. Install or connect the following:
    NOTE
    The thrust plate positions for the right and left cylinder head camshafts are different.



    Lifters in their original positions lubricated with engine oil. Verify that they move smoothly in their bore.
     
    Camshafts by lubricating the camshaft journals, lobes and gears with clean engine oil and aligning the timing marks
     



    Click image to see an enlarged view

    Fig. When installing the camshafts, ensure that the marks on the cam gears are aligned-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Put silicone sealant on the cylinder head at the positions shown-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Front camshaft cap bolt tightening sequence-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.5L (KL) engines

  2.  
  3. Be sure the camshaft cap and cylinder head surfaces are clean. Apply a small amount of sealant to the mating surface of the front camshaft cap on both cylinder heads and the rear exhaust camshaft cap on the left cylinder head. Do not get any sealant on the camshaft rotating surfaces.
  4.  
  5. Install or connect the following:
    NOTE
    On the right cylinder head, install the sprocket so the R mark can be seen and the timing mark aligns with the camshaft knock pin. On the left cylinder head, install the sprocket so the L mark can be seen and the timing mark aligns with the camshaft knock pin.



    Front camshaft caps and thrust plate caps. Torque the bolts until the cap seats fully to the cylinder head.
     
    Remaining caps in their original locations. Torque the bolts in 5-6 steps to 126 inch lbs. (14 Nm), in the proper sequence.
     
    New oil seals in the cylinder head using an installer
     
    New blind cap coated with sealant, tap it in place using a plastic hammer
     
    Camshaft sprockets
     



    Camshaft sprocket bolts lubricated with engine oil, by holding the camshaft with a wrench on the cast hexagon. Torque the bolt to 97 ft. lbs. (132 Nm).
     
    Cylinder head cover
     
    Alternator stay
     
    Front exhaust pipe
     
    Seal plate
     
    Number 3 engine mount bracket
     
    Water outlet
     
    Upper radiator hose
     
    Intake manifold
     
    Distributor and spark plug wires
     
    Air cleaner assembly
     
    Timing belt
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Change the oil and filter.
  10.  
  11. Run the engine and check for proper operation.
  12.  

 
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